Differential mechanism for an automotive vehicle having a cold formed housing assembly

A differential mechanism, comprising:

• a first housing portion having a first wall, a first surface located on an exterior surface of the first wall, and first recesses located on the first wall and spaced angularly about a central axis;
• a second housing portion having a second wall, a second surface located on an interior surface of the second wall, the first and second surfaces being mutually adjacent, overlapping, and facing, the first and second housing portions being permanently and non-removably connected at the first and second surfaces, second recesses located on the second wall, each second recess aligned angularly with a corresponding first recess thereby forming recess pairs, said recess pairs aligned on a transverse axis;
• a pinion shaft located within a space surrounded by the walls of the housing portions, extending along the transverse axis, having opposite axial ends, each end located in a respective recess pair;
• bevel pinions supported on the pinion shaft for rotation about the transverse axis;
• and
• side bevel gears in continuous meshing engagement with the bevel pinions.

A differential mechanism, comprising:

• a first housing portion having a first wall and first recesses located on the first wall, spaced angularly about a central axis;
• each first recess being a semicircular cylindrical surface extending through the first wall;
• a second housing portion permanently connected to the first housing portion, said second housing portion having a second wall, second recesses located on the second wall, each second recesses being aligned angularly with a corresponding first recess of said first recesses thereby forming recess pairs aligned on a transverse axis;
• each second recess being a semicircular cylindrical surface complementary to the its first recess and extending radially partially through the second wall, each recess pair forming substantially a circular cylinder, said recess pairs being mutually facing, aligned angularly and radially about the central axis, and spaced on the transverse axis substantially perpendicular to the central axis;
• a ring gear surrounding and permanently connected to an exterior surface of one of said housing portions;
• a pinion shaft located within a space surrounded by the walls of the housing portions, extending along the transverse axis, having opposite axial ends, each end located in a respective recess pair of said recess pairs;
• bevel pinions supported on the pinion shaft for rotation about the transverse axis;
• and
• side bevel gears in continuous meshing engagement with the bevel pinions.

A differential mechanism, comprising:

• a first housing portion having a first wall, a first surface located on an exterior surface of the first wall, and first recesses located on the first wall and spaced angularly about a central axis;
• a second housing portion having a second wall, a second surface located on an interior surface of the second wall, the first and second surfaces being mutually adjacent, overlapping, and facing, the first and second housing portions being permanently connected at the first and second surfaces, second recesses located on the second wall, each second recess aligned angularly with a corresponding first recess thereby forming recess pairs, said recess pairs aligned on a transverse axis;
• a flange formed integrally with one of said housing portions, extending radially outward from the axis;
• a ring gear surrounding and permanently connected to an exterior surface of a housing portion, the ring gear being substantially coaxial with the central axis and surrounding and being permanently connected to the flange;
• a pinion shaft located within a space surrounded by the walls of the housing portions, extending along the transverse axis, having opposite axial ends, each end located in a respective recess pair;
• bevel pinions supported on the pinion shaft for rotation about the transverse axis;
• and
• side bevel gears in continuous meshing engagement with the bevel pinions.